JPH07205123A - Concrete product with elastic surface layer and manufacture thereof - Google Patents

Abstract

PURPOSE:To prevent peeling of a surface plate from concrete by mounting legs each having a protrusion on a rear surface of the plate of an elastic surface frame, adhering an elastic intermediate buffer layer, and filling concrete between the legs to absorb expansion, contraction of the frame. CONSTITUTION:A surface plate 11, two legs 12 suspended from opposed lines of the plate, and protrusion 13 protruding inward from intermediate parts of the legs are integrally provided to form an elastic surface frame. The frame is formed by integrating elastic chips by binder in a molding form 1 for the frame. An elastic intermediate buffer 20 is adhered to the surface of the plate 11, ready mixed concrete is placed on the buffer 20 to be filled between the legs 12 to form a concrete layer 30, and then released from the form 1. The buffer 20 is formed of a foamed sponge layer. Accordingly, even if the frame 1 is expanded or contracted, the frame 1 is integrally coupled to the layer 30 and prevented from being peeled.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to an elastic surface layer suitable for paving walls, floors, sidewalks, plazas, etc. of buildings such as hospitals and nursing homes, and for forming retaining walls for ball stadiums, circuit courses, etc. And a method for manufacturing the same.

[0002]

2. Description of the Related Art A water-permeable elastic covering material or a non-water-permeable elastic covering material in which elastic chips such as granular or string-like synthetic rubber and urethane rubber are combined with a binder and processed into a plate shape of various sizes. Are commercially available, for example, as Super Block and Super Road (trade name of Nitto Kako Co., Ltd.).
This elastic covering material is attached to a molded and solidified concrete layer with a synthetic adhesive to make products for walls, floors, paving, retaining walls, etc.

[0003]

The expansion and contraction of the elastic covering material due to the temperature change is significantly larger than the expansion and contraction of the concrete layer by about 30,000 to 60,000 times. For this reason,
When the product is used on walls, floors, pavements and retaining walls, it expands significantly,
The peripheral part of the elastic covering material that contracts peels from the concrete layer over the course of time, and during that time water enters and rots, and it starts to give off a bad odor, or the water that entered during that time freezes and increases in volume, The peeling area of the peripheral portion of the elastic covering material is increased. When it is used by spreading it on the floor of a hospital or nursing home, the peeled peripheral parts of the elastic covering materials of adjacent products abut and expand, which causes the patient and the elderly to trip over it. There is a risk of injury. There is also a product manufactured by partially embedding the embedded legs on the back surface of the elastic covering material and embedding the embedded legs in concrete, but in the case of this product, it is at the intermediate part between the embedded legs. The elastic covering material peels off from the concrete layer, and air enters the middle part of the peeled elastic covering material and the middle part of the concrete covering layer, or the middle part of the elastic covering material rises, and water enters into it, causing it to rot and foul odor. Or the water in it freezes and increases in volume, cracking the middle part of the elastic covering material that has no escape.

[0004]

SUMMARY OF THE INVENTION The present invention relates to a concrete product having an elastic surface layer which does not cause the above-mentioned problems even if it expands or contracts due to temperature change, and a method for producing the same. Includes a surface plate portion, a leg portion that hangs from opposite edges of the surface plate portion, and a T-shaped or L-shaped protrusion that protrudes inward from the middle of the facing surface of each leg portion. An elastic front frame formed by coupling elastic chips, an elastic intermediate cushioning material attached to the back of the surface plate portion of the elastic front frame, and the opposing legs filled under the intermediate cushioning material It has a concrete layer that fills between the parts integrally, the intermediate cushioning material is different from the elastic table frame and concrete, and is adapted to absorb expansion and contraction of the elastic table frame due to temperature change. To do. in this case,
The elastic intermediate cushioning material is sprayed and fixed on the three-dimensional fiber layer on both sides of the elastic surface frame and the concrete layer, or on the sponge layer, or on the back surface of the elastic surface frame to fix it to the concrete layer It is preferably a foamed sponge layer of synthetic resin adhered. The concrete product according to claim 4 is characterized in that a surface plate portion, legs extending from opposite edges of the surface plate portion, and a T shape projecting inward from the middle of the facing surfaces of each leg portion, Or a water-permeable concrete having an L-shaped projection and formed by connecting elastic chips to each other, and a water-permeable concrete that is filled in the back of the surface plate of the elastic table and fills between the opposing legs. It is characterized by being composed of layers. The method for manufacturing a concrete product according to claim 5 includes a surface plate portion,
Legs that hang from opposite edges of the surface plate, and T-shapes that project inward from the middle of the facing surfaces of the legs,
Alternatively, an elastic table frame having L-shaped projections is molded by combining elastic chips, and the elastic table frame is different from concrete on the back surface of the surface plate portion of the elastic table frame and the elastic table due to temperature change. It is characterized in that an elastic intermediate cushioning layer that absorbs expansion and contraction of the frame is attached, and then concrete is filled between the opposing legs of the elastic table frame. The method for manufacturing a concrete product according to claim 6, wherein the surface plate portion, the leg portions that hang down from the opposite edges of the surface plate portion, and the T-shape that protrudes inward from the middle of the mutually facing surfaces of the leg portions. Alternatively, a water-permeable elastic surface frame having L-shaped protrusions is formed by connecting elastic chips, and water-permeable concrete is filled between the opposing leg portions of the elastic surface frame.

[0005]

Embodiment In the illustrated embodiment, 10 is an elastic frame,
A square surface plate portion 11, two leg portions 12 and 12 hanging from opposite edges of the front plate portion, and a protrusion (in the figure, L-shaped in the figure) protruding inward from the middle of the facing surface of each leg portion. However, it may be a T-shaped one as shown by the broken line)
13 integrally. This elastic front frame 10 is made of synthetic rubber,
Granular or string-like elastic chips such as urethane rubber are molded by binding with a binder in a molding frame for an elastic table frame. Even if water impermeable, the amount of binder used is adjusted to May have water permeability such that adjacent elastic chips are coupled to each other without filling the gap between the adjacent elastic chips. The thickness of the surface plate 11 is about 10 to 20 mm, the height from the upper surface of the surface plate to the lower end of the leg 12 is 40 to 60 mm, and the thickness of the leg is 10 to 15.
mm, the size of the surface plate portion may be any size that can be molded, such as 300 mm square to 1000 mm square. The shape may be square or rectangular.

3 and 4 are cross-sectional views of the elastic frame forming process. First, the elastic chip and the binder are flatly placed in the molding frame (mold) 1 and heated and compressed by a press to form the surface plate portion 11.
Then, the two inner mold plates 2 and 2 and the core plate 3 positioned between them are overlapped on the surface plate part 11, and the base parts of the two legs are formed between the mold plate and the inner mold plate. Keeping the space in the mold, and then stacking the inner mold 4 on the inner mold plate and the core plate to fill the space between the protrusions facing each other of the two legs, and to fix both inner mold plates and the inner mold. After filling the required amount of elastic tip and binder between the frame and the inner mold plate, the auxiliary L-shaped auxiliary mold 5,
5 is pushed in to form the two leg portions 12, 12 with the projections, and the surface plate portion 11 is integrally removed from the mold. Two inner mold plates 2 and 2 sandwiching the core plate 3 are located between the surface plate portion 11 and the protrusions 13 and 13. The inner mold plates are removed by first removing the core plate 3. It can be easily demolded by moving it to the center. In addition, when the protrusion is T-shaped, the shallow groove 2 that forms the protrusion on the core plate 2
In order to remove the mold, the core plate is removed, and then the groove 2'can be forcibly removed from a part of the projection filling the groove 2'using the elasticity of the projection. Further, as shown in FIGS. 5 and 6, the core 4 and the L-shaped auxiliary molds 5 and 5 are arranged at the bottom of the molding mold 1, and the core and the space between the auxiliary molds 5 and 5 and the mold 1 are arranged. After filling the required amount of elastic tip and binder in the above, the press dies 6 and 6 are pushed in to form the leg portions 12 and 12 with protrusions first, and then the elastic tip is attached on both leg portions and on the core 4. The surface plate portion 11 may be formed by filling a binder and heating and compressing with a press. To make the protrusion 13 T-shaped, press die 6,6 L
It is sufficient to use a shaped cross section.

In order to manufacture the concrete product of claim 1, an elastic intermediate cushioning material 20 is attached to the back surface of the front surface plate portion 11 of the elastic front frame, the elastic front frame is turned over, and the leg portions 12 of the front surface plate portion 11, It is housed in a mold 6 that closes the end portion that does not have 12 (see FIG. 7), and the surface of the intermediate cushioning material is composed of an adhesive agent, such as epoxy-based polysulfide, which is adhesive and hardened even with fresh concrete containing a large amount of water. A synthetic adhesive is applied, and fresh concrete such as cement concrete or resin concrete is poured on the synthetic adhesive to fill the space between the two legs 12 and 12, and when the concrete layer 30 is solidified, the mold is removed.

The elastic intermediate cushioning material 20 may be a thick non-woven fabric, a three-dimensional fiber layer such as a sheet or mesh fluffed by spraying various fibers and binding them with a binder, or a sheet of a permanent woven carbon fiber. The layer may be a sponge layer or a synthetic resin sponge-like foamed layer, which basically has a certain thickness (5 to 10 mm) and is smaller in expansion and contraction due to temperature change than the elastic covering material. ,
It should be larger than the concrete layer.

When the elastic intermediate cushioning material 20 is attached to the back surface of the face plate of the elastic front frame, even if the intermediate cushioning material is a fiber three-dimensional layer or a sponge layer, even if the intermediate cushioning material is bonded with an adhesive, it is heated and fused by pressing and pressure bonding. Good. When the intermediate cushioning material is a foam sponge layer, a foaming agent-containing synthetic resin that foams to form a sponge may be sprayed on the back surface of the front surface plate portion 11 of the elastic frame. In this case, a large number of grooves having a width of about 5 mm and a depth of about 3 mm are formed at appropriate intervals on the back surface of the front surface plate portion, and when a synthetic resin containing a foaming agent is sprayed onto the grooves, the resin is applied to the back surface of the front surface plate portion and the back surface. Since the formed groove is filled and fixed, the attachment strength of the foam sponge layer to the surface plate portion is significantly improved. When the concrete layer 30 is water permeable, the adhesive or the adhesive for adhering the intermediate cushioning material and the concrete layer adheres in a striped pattern or a grid pattern so that the adhesive does not impede water permeability. At the same time, the sponge of the sponge layer is made water-permeable so that the moisture adhering to the surface of the surface plate of the elastic front frame can permeate the water-permeable concrete layer.

In order to manufacture the concrete product of claim 4, the elastic front frame is turned upside down, and the legs 12, 12 of the surface plate portion 11 are manufactured.
It is housed in a mold 7 that closes the end portion that does not have (see FIG. 8), and an adhesive that is hardened together with concrete is applied to the back surface of the surface plate portion in a striped or grid pattern, and cement concrete, A ready-mixed concrete having a water-permeable mixture such as resin concrete is poured and filled between the two leg portions 12 and 12, and when the water-permeable concrete layer 31 is solidified, the mold is removed.

When manufacturing the product according to claim 1, the method according to claim 4 is also applied.
In the case of manufacturing the product of, the cement paste around the surface plate part of the elastic table frame is hardened by the cement paste when the fresh concrete is placed. A water-soluble leak-proof tape 32 is previously attached to the above with a water-soluble adhesive. This water-soluble leakproof tape 32
Is a pulp or a water-absorbent vinylon or other water-absorbing fiber that swells in water and is bound with a water-soluble binder such as CMC (sodium fibrin glycolate) to a thickness of 0.1 to 0.
A tape with a thickness of about 3 mm and a thickness of 0.1 mm will be about 2.5 in about 3 to 5 seconds when contacted with water.
It swells to a mm and becomes a gel or soft clay like 1
The 0 mm square absorbs water and spreads out to about 12 to 14 mm square. If this leak-proof tape 32 is attached around the surface of the surface plate part, when the ready-mixed concrete is placed and the cement paste tries to wrap around the surface of the face plate part, the leak-proof tape will be in the cement paste. Instantaneously absorbs water and swells, and prevents the cement paste from wrapping around the surface of the elastic covering material. Therefore, the surface of the elastic covering material is not contaminated with the cement paste. It can be easily removed by washing the product with water.

In the illustrated embodiment, the leg portions 12 are provided on the two opposite sides of the surface plate portion, but they may be provided so as to be surrounded along the four sides.

[0013]

As is apparent from the above, the concrete product according to the present invention has a shape in which the elastic front frame holds the concrete layer or the water permeable concrete layer on the back of the surface plate portion with two or four legs. Hold in. Then, the L-shaped or T-shaped projections provided inwardly on the two legs are embedded in the concrete layer or the permeable concrete layer. Therefore, even if the elastic table frame expands or contracts due to a change in temperature, the elastic table frame and the concrete layer or the water-permeable concrete layer are integrally bonded and are not separated from the legs. In the product of claim 1, the surface plate portion is connected to the concrete layer through an elastic intermediate cushioning material capable of absorbing expansion and contraction due to temperature change of the elastic surface frame. Therefore, when the elastic covering material greatly expands and contracts, the surface of the elastic intermediate cushioning material that is attached to the elastic table frame also expands and contracts similarly, but the rate of expansion and contraction of the surface that adheres to the concrete layer is elastic. Much less than cover materials. As a result, the elastic intermediate cushioning material absorbs the expansion and contraction of the elastic covering material and makes it 1 / 30,000 to 60,000 or less and transmits it to the concrete layer, so that the surface plate part does not peel off from the concrete layer and water enters between them. There is no room for problems such as rusting and cracking of the surface plate. Further, in the product of claim 2, the surface plate portion of the elastic outer frame is used as the surface, and the moisture adhering thereto can be permeated to the ground through the permeable concrete layer. When the concrete product according to claim 1 or 2 is laid to pave a building wall or floor, a sidewalk, a plaza, or stacked to form a retaining wall, a sealant is applied to a joint (joint) between the products. By injecting, it is possible to construct walls, floors, sidewalks, plazas, retaining walls, etc. that have elasticity on the surface in a short period of time. Claim 5,
According to claim 6, a surface plate part formed by combining elastic chips, two leg parts hanging from both ends of the surface plate part, and inwardly from the middle of the facing surfaces of each leg part. Turn over the elastic front frame with protruding T-shaped or L-shaped protrusions,
By placing concrete or permeable concrete ready-mixed concrete between both legs, the elastic front frame facilitates concrete products with two or four permeable concrete layers on the back of the surface plate. Can be molded into.

[Brief description of drawings]

FIG. 1 is a perspective view of an example of a concrete product according to claim 1.

FIG. 2 is a perspective view of an example of the concrete product of claim 4.

FIG. 3 is a cross-sectional view of a first stage of a first molding example of the elastic front frame.

FIG. 4 is a cross-sectional view of a second stage of the molding state of the elastic frame.

FIG. 5 is a sectional view of a first stage of the second molding example of the elastic front frame.

FIG. 6 is a cross-sectional view of the second stage of the molding state of the elastic front frame.

FIG. 7 is a sectional view of the concrete product of claim 1 in a manufactured state.

FIG. 8 is a sectional view of the concrete product of claim 4 in a manufactured state.

[Explanation of symbols]

 1 Elastic Formwork Forming Form 2 Inner Form Plate 3 Inner Plate 4 Inner Form 5 Stamping Form 6 Product Form Form 7 Product Form Form 10 Elastic Front Form Frame 11 Surface Plate Part 12 Legs 13 Protrusion 20 Elastic Intermediate Buffer Material 30 Concrete layer 31 Water-permeable concrete layer 32 Leakage prevention tape

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display area E04F 15/08 7416-2E 15/10 103 7416-2E

Claims (6)

[Claims] 1. A surface plate part, leg parts hanging from opposite edges of the surface plate part, and T-shaped or L-shaped protrusions protruding inward from the middle of the facing surfaces of the respective leg parts. With and
An elastic front frame formed by combining elastic chips, an elastic intermediate cushioning material attached to the back of the surface plate portion of the elastic front frame,
It has integrally with a concrete layer filled under the intermediate cushioning material and filling the space between the opposed leg portions, the intermediate cushioning material is an elastic table frame, and an elastic table frame which is different from concrete and changes due to temperature change. A concrete product having an elastic surface layer characterized by absorbing expansion and contraction of the concrete. 2. The concrete product according to claim 1, wherein the intermediate cushioning material is a three-dimensional fiber layer in which both surfaces are adhered to the elastic outer frame and the concrete layer, or a sponge layer. A concrete product having a surface layer. 3. The concrete product according to claim 1, wherein the intermediate cushioning material is made of synthetic resin which is sprayed and bonded to the back surface of the surface plate portion of the elastic front frame and bonded to the concrete layer. A concrete product having an elastic surface layer, which is a sponge layer. 4. A surface plate portion, legs extending from opposite edges of the surface plate portion, and T-shaped or L-shaped protrusions that project inwardly from the middle of the facing surfaces of each leg portion. With and
A water-permeable elastic table frame formed by connecting elastic chips,
A concrete product having an elastic surface layer, characterized in that it comprises a water-permeable concrete layer that is filled on the back of the surface plate part of the elastic surface frame and fills the space between the facing leg parts. 5. A surface plate portion, legs extending from opposite edges of the surface plate portion, and T-shaped or L-shaped protrusions that project inwardly from the middle of the facing surfaces of each leg portion. An elastic table frame provided with and is molded by bonding elastic chips, and this elastic table frame is turned over, and the elastic table frame is on the back surface of the surface plate portion, and of the elastic table frame that is different from concrete and changes due to temperature change. expansion,
A method for producing a concrete product having an elastic surface layer, characterized in that an elastic intermediate buffer layer that absorbs shrinkage is attached, and then concrete is filled between the opposing legs of the elastic surface frame. 6. A surface plate part, legs extending from opposite edges of the surface plate part, and T-shaped or L-shaped protrusions protruding inward from the middle of the surfaces of the legs facing each other. A concrete having an elastic surface layer, characterized in that a water-permeable elastic surface frame having and is molded by connecting elastic chips, the elastic surface frame is turned over, and water-permeable concrete is filled between the facing legs. Product manufacturing method.